Emissions Theory and Diagnostics

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1 SECTION 1 Introduction 5-Gas Theory Emissions History OBD II SECTION 2 PCV System Function Failure Diagnosis Emissions Theory and Diagnostics SECTION 3 EGR EGR Theory Vacuum Systems Backpressure Systems DPFE Systems Linear Systems SECTION 4 O 2 Sensors & Fuel Control Performance Testing Heater Testing Fuel Trim Diagnosis SECTION 5 Converters & AIR Injection Converter Theory Efficiency Testing AIR System Theory AIR System Testing SECTION 6 EVAP EVAP Overview Leak Testing Component Testing Efficiency Testing

2 SECTION 1: INTRODUCTION INTRODUCTION CONTENTS INTRODUCTION The 5 Gases Overview Basic Combustion Chemistry Carbon Dioxide (CO 2 ) & Oxygen (O 2 ) Hydrocarbons (HC) & Carbon Monoxide (CO) Oxides of Nitrogen (NO X ) Normal Gas Levels Gas Relationships Catalyst Gas Conversion Diagnosing by Gas Failure Emissions Repair Warning History of Emissions Controls Overview PCV Systems EPA Formation EGR Systems High-Energy Ignition Systems Catalytic Converters EPA Timeline Computerized Feedback Fuel Control Systems The 1990 Clean Air Act Alternative Fuels & Service Information Rules Motor Vehicle Owners Right to Repair Act of OBD II Systems OBD II Overview Monitor Trips & Drive Cycles Similar Conditions Continuous & Non-Continuous Monitor Overview Comprehensive Component Monitor (CCM) Explanation Monitor Testing Overlap Drive Cycle Vehicle Preparation Example OBD II Drive Cycle Example Drive Cycle Tips Inspection/Maintenance (I/M) System Check Unmonitored Components, Circuits, & Systems New Monitors Secondary Air Monitor Enhancement PCV Monitor Communication & I/M Problem Vehicles Readiness Monitor Status Anomalies OBD II Serviceability Issues TSB

3 SECTION 2: PCV PCV CONTENTS POSITIVE CRANKCASE VENTILATION PCV System Construction & Function Positive Crankcase Ventilation (PCV) PCV Operation PCV Failures Daimler Chrysler System Variations PCV Solenoid L Hemi PCV Variations

4 SECTION 3: EGR EGR CONTENTS EXHAUST GAS RECIRCULATION SYSTEMS Construction & Function EGR Principles Daimler Chrysler EGR Monitor & Codes EGR System Monitor Flow Fault Codes Daimler Chrysler Vacuum EGR Vacuum EGR Valve Introduction Solenoids & Transducers Scan Tool Solenoid PID Test Scan Tool Bi-Directional Controls Lab Scope Solenoid Test Vacuum EGR System Wiring Diagram Daimler Chrysler Linear EGR Linear EGR Valve Introduction Linear EGR Valve Circuits & Operation Lab Scope Linear EGR Valve Test Lab Scope EGR Position Sensor Test Solenoid Circuit Fault Code Position Sensor Fault Codes Linear EGR System Wiring Diagram Ford DPFE EGR EGR System Overview Vacuum Management Overview (Solenoid) Solenoid Resistance Testing Solenoid Scan Tool PIDs Solenoid Lab Scope Test Solenoid Current Test Solenoid Scan Tool & Voltage Test Solenoid Functional Testing Differential (or Delta) Pressure Feedback (DPFE) Sensor DPFE Sampling Common DPFE Faults Trouble Codes EGR Performance Trouble Codes Solenoid Trouble Codes DPFE Sensor Scan Tool DPFE Test Null Value Scan Tool DPFE Test Normal Operation Scan Tool DPFE Test Fault Example Lab Scope EGR Flow Test EGR System Monitor EGR System Wiring Diagram

5 SECTION 3: EGR EGR CONTENTS EXHAUST GAS RECIRCULATION SYSTEMS General Motors Digital EGR Digital EGR Valve Overview Integrated Electronic EGR Valve Overview Linear EGR Valve Introduction Operating Conditions Linear EGR Valve Circuits & Operation Flow Fault Code Position Fault Codes Control Circuit Fault Code Linear EGR Bi-Directional & DVOM Test Linear EGR Valve & Sensor Test EGR System Monitor EGR System Wiring Diagram

6 SECTION 4: OXYGEN SENSORS & FUEL CONTROL OXYGEN SENSORS & FUEL CONTROL CONTENTS OXYGEN SENSORS Sensor Construction & Function Sensor Introduction & Identification Sensor Operation Downstream Sensor Fuel Control Sensor Heaters Daimler Chrysler Oxygen Sensors Sensor Circuits & Heater Circuits Sensor Testing Overview Miscalibration Faults Scan Tool Tests Time-To-Activity test Expected HO2S Activity HO2S Signal Hash Slow Response Test HO2S Monitor Upstream HO2S Monitor Downstream Heater Testing Overview Heater Scan Tool Test Heater Bi-Directional Test Heater Voltage Tests JTEC, SBEC, & NGC Heater Diagnostic Pulse Test - NGC HO2S Heater Monitor HO2S Trouble Codes HO2S Heater Control Circuit Trouble Codes HO2S Heater Performance Trouble Codes HO2S Wiring Diagrams Ford Oxygen Sensors Sensor Circuits & Heater Circuits Sensor Testing Overview Time-To-Activity Test Slow Response Test Expected HO2S Activity (Cruise) Sticky Sensor Fault Example HO2S Monitor & Trouble Codes Heater Testing Overview Heater Scan Tool Testing Heater Resistance Testing Heater Circuit Voltage & Current Testing HO2S Heater Monitor & Trouble Codes HO2S Wiring Diagrams

7 SECTION 4: OXYGEN SENSORS & FUEL CONTROL OXYGEN SENSORS & FUEL CONTROL CONTENTS OXYGEN SENSORS General Motors Oxygen Sensors Sensor Circuits Heater Circuits Sensor Testing Overview Scan Tool Test Time-To-Activity Test Slow Response Test Expected HO2S Activity (Cruise) HO2S Monitor Heater Testing Overview Heater Scan Tool Testing Heater Bi-Directional Testing Heater Voltage Testing HO2S Heater Monitor HO2S Trouble Codes HO2S Heater Trouble Codes HO2S Wiring Diagrams Wide Range Sensor Introduction & Advantages WRAF Circuits WRAF Sensor Operation Scan Tool Testing Lambda Lambda Values WRAF Sensor Diagnosis Fuel Trim Basic Fuel Control Open & Closed Loop General Motors Closed loop Variations Adaptive Fuel Control (Fuel Trim) Fuel Trim Units & Range General Motors Fuel Trim Units Long & Short term Fuel Trim Relationship Fuel Trim & HO2S Relationship Fuel Trim Tables Fuel Trim Reset Diagnosing By Resetting Fuel Trim Daimler Chrysler, Ford, & GM Scan Tool Tests Simplified Fuel Trim Monitor Explanation Fuel Trim Monitor Daimler Chrysler, Ford, & General Motors Fuel Trim Trouble Codes

8 SECTION 5: CONVERTERS & AIR INJECTION CONVERTERS & AIR INJECTION CONTENTS CATALYTIC CONVERTERS Construction & Function The Need for Catalysts & Catalyst Types Catalyst Operating Temperatures Catalyst Failures & Air Injection Reaction Systems Converter Chemistry Catalyst Effectiveness & Catalyst Monitor Logic Daimler Chrysler Monitor Conditions SBEC, JTEC, & NGC Catalyst Monitors Catalyst Efficiency Trouble Codes Ford Motor Company Converter Efficiency Monitor & Switch Ratio Method Switch Ratio Driving Pattern Index Ratio Method & General Catalyst Monitor Operation Trouble Codes General Motors Converter Efficiency Monitor Converter Efficiency Monitor Logic Catalyst Efficiency Trouble Codes Catalyst Efficiency Testing Catalyst Testing Overview & Rattle Test Exhaust Backpressure & Catalyst Temperature Tests Gas Analyzer Test Before & After and Cranking HC Catalyst Scan Tool Test AIR PUMPS Air Injection Overview General Operating Modes & Belt Driven Systems Belt Driven System Wiring Example Ford Electric Air Pumps Electric Air Pump Overview & Operation Bypass Solenoids & System Scan Tool Testing Electric Air Pump Fault Example Air Pump Current Test Secondary Air Monitor & Trouble Codes Electric Pump System Wiring Diagram General Motors Electric Air Pumps Air Injection Overview Air Injection Components System Disabling Conditions AIR System Diagnosis & Bi-Directional Test Air Pump Current Test & System Trouble Codes

9 SECTION 6: EVAP SYSTEMS EVAP SYSTEMS CONTENTS EVAPORATIVE EMISSIONS SYSTEMS Construction & Function The Hydrocarbon Problem EVAP System Overview EVAP System Components Charcoal Canister System Vapor Flow Canister Vapor Flow Canister Failures Purge Solenoid Solenoid Faults Solenoid Controls EVAP System Test Port & Vent Solenoid Daimler Chrysler Typical EVAP System Graphics Purge Solenoid Trouble Codes Proportional Purge Solenoid Purge Sense Scan Tool Purge Solenoid Test Scan Tool Bi-Directional Tests KOEO Scan Tool Bi-Directional Tests KOER DVOM/GMM Purge Solenoid Test Lab Scope Purge Solenoid Test Conventional Purge Solenoid Current Test Conventional Lab Scope Purge Sense Test Proportional Lab Scope Purge Solenoid Test Proportional Onboard Refueling Vapor Recovery (ORVR) EVAP Monitor Overview Purge Flow Monitor Conditions SBEC Purge Flow Monitor Conditions JTEC Purge Flow Monitor Conditions NGC Purge Flow Monitor Process Leak Detection Pump System Introduction EVAP System Leak & Performance Codes LDP LDP Solenoid Trouble Codes LDP Switch Trouble Codes LDP EVAP Monitor Differences LDP Monitor Explanation LDP Pump Mode LDP Test Mode Missing/Loose Gas Cap

10 SECTION 6: EVAP SYSTEMS EVAP SYSTEMS CONTENTS EVAPORATIVE EMISSIONS SYSTEMS Daimler Chrysler - Continued LDP System TSB Scan Tool Bi-Directional Tests LDP EVAP Monitor Lab Scope Test LDP Solenoid Lab Scope Test LDP Monitor Natural Vacuum Leak Detection (NVLD) Overview NVLD Components NVLD Solenoid EVAP System Leak & Performance Codes NVLD NVLD Component Trouble Codes NVLD Rationality & Flow Check NVLD Small Leak Test NVLD Medium & Large Leak Test NVLD Switch Trouble Codes NVLD Scan Tool PID Test NVLD Solenoid Current Testing Lab Scope NVLD Solenoid Test EVAP System Wiring Diagrams Ford Motor Company Ford-Specific Component Overview System Vapor Flow Vent Solenoid Trouble Codes Vent Solenoid Scan Tool PID Test Vent Solenoid Scan Tool Bi-Directional Test Vent Solenoid Resistance Test Purge Solenoid/Vapor Management Valve Purge Solenoid/VMV Trouble Codes Purge Solenoid/VMV Resistance Test Purge Solenoid/VMV Scan Tool Test Lab Scope Purge/VMV Solenoid Test Purge Solenoid/VMV Current Test Purge Flow Sensor & Sensor Testing Fuel Tank Pressure Sensor Pressure Sensor Calibration Fuel Tank Pressure Sensor Trouble Codes Pressure Sensor Scan Tool Test Onboard Refueling Vapor Recovery (ORVR) EVAP Monitor Drive Cycle

11 SECTION 6: EVAP SYSTEMS EVAP SYSTEMS CONTENTS EVAPORATIVE EMISSIONS SYSTEMS Ford Motor Company - Continued EVAP Monitor Process Monitor Trouble Codes EVAP Monitor Some Late Model Late Monitor Type Overview Leak Check Overview Monitor Enabling Conditions Monitor Abort Conditions For Phase Phase 0: Vacuum Build Phase 1 & 2: Vacuum Stabilization & Vacuum Hold & Decay Phase 3 & 4: Vacuum Release & Vapor Generation Idle Check Late Monitor Trouble Codes & Fail Thresholds Engine Off Natural Vacuum (EONV) Leak Check EONV Phases EONV Trouble Codes Monitor Scan Tool Trick EVAP System Wiring Diagrams General Motors Enhanced EVAP System Implementation & System Vapor Flow Typical EVAP System Graphic Charcoal Canister Canister Vapor Flow Vent Solenoid Vent Solenoid Trouble Codes Purge Solenoid EVAP System Test Port Purge Solenoid Trouble Codes Scan Tool Test - Vent & Purge Solenoids Scan Tool Bi-Directional Tests Combination Testing Scan Tool Service Bay Test Vent Solenoid Lab Scope & Current Test Purge Solenoid DVOM Test Purge Solenoid Lab Scope Test Fuel Tank Pressure Sensor Fuel Tank Pressure Sensor Trouble Codes FTP Sensor Scan Tool Test

12 SECTION 6: EVAP SYSTEMS EVAP SYSTEMS CONTENTS EVAPORATIVE EMISSIONS SYSTEMS General Motors - Continued FTP Sensor Bi-Directional Test Onboard Refueling Vapor Recovery (ORVR) EVAP Monitor Drive Cycle EVAP Monitor Process & Check Gas Cap Message Engine Off Natural Vacuum (EONV) Leak Check EONV Stages EONV Enabling Conditions EONV Volatility Test EONV Pressure Test EONV Vacuum Test EONV Test Results Scan Tool Testing Tip EVAP System Wiring Diagram

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